CA2158241A1 - Shoe-wiping mat for rent - Google Patents
Shoe-wiping mat for rentInfo
- Publication number
- CA2158241A1 CA2158241A1 CA002158241A CA2158241A CA2158241A1 CA 2158241 A1 CA2158241 A1 CA 2158241A1 CA 002158241 A CA002158241 A CA 002158241A CA 2158241 A CA2158241 A CA 2158241A CA 2158241 A1 CA2158241 A1 CA 2158241A1
- Authority
- CA
- Canada
- Prior art keywords
- mat
- base fabric
- taffeta
- width
- stitches
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Classifications
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47L—DOMESTIC WASHING OR CLEANING; SUCTION CLEANERS IN GENERAL
- A47L23/00—Cleaning footwear
- A47L23/22—Devices or implements resting on the floor for removing mud, dirt, or dust from footwear
- A47L23/26—Mats or gratings combined with brushes ; Mats
- A47L23/266—Mats
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H11/00—Non-woven pile fabrics
-
- D—TEXTILES; PAPER
- D05—SEWING; EMBROIDERING; TUFTING
- D05C—EMBROIDERING; TUFTING
- D05C17/00—Embroidered or tufted products; Base fabrics specially adapted for embroidered work; Inserts for producing surface irregularities in embroidered products
- D05C17/02—Tufted products
- D05C17/026—Tufted products characterised by the tufted pile surface
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
- D06N7/0092—Non-continuous polymer coating on the fibrous substrate, e.g. plastic dots on fabrics
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2203/00—Macromolecular materials of the coating layers
- D06N2203/06—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- D06N2203/061—Polyesters
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2209/00—Properties of the materials
- D06N2209/08—Properties of the materials having optical properties
- D06N2209/0807—Coloured
Abstract
A shoe-wiping mat with color pattern for rent, having a novel taffeted texture and, particularly, a shoe-wiping mat with color pattern for rent, having vivid color pattern, excellent softness, dust-adsorbing property and dust-holding property, preventing undulation phenomenon on the mat surface even after used repetitively, and having excellent fitness to the floor surfaces. A row of taffeta stitches in the direction of width of the base fabric is slightly tilted relative to the direction of width of the base fabric and is formed in a zig-zag shape from a folding point on one side to a folding point on the other side maintaining a predetermined distance in the direction of width and a small distance in the lengthwise direction, thereby to form a belt-like row of taffeta stitches which as a whole extends in the lengthwise direction of the base fabric, boundary lines connecting the folding points which are neighboring in the lengthwise direction of taffeta stitches are formed in a zig-zag shape having a pitch greater than the pitch between said folding points, the folding points of the belt-like row of taffeta stitches neighboring in the direction of width of the base fabric are positioned on common zig-zag boundary lines, the folding points of the belt-like row of one side are positioned at the centers of the folding points which are neighboring in the lengthwise direction of the belt-like row of the other side, mat piles have a plurality of mat pile surfaces of different hues, the mat piles without at all containing dead yarns, and at least one unstitched portion exists between the neighboring mat pile surfaces of different hues.
Description
~lS8~41 TITLE OF THE INVENTION
SHOE-WIPING MAT FOR RENT
BACRGROUND OF THE INVENTION
(Field of the Invention) The present invention relates to a shoe-wiping mat with color pattern for rent, having a nov@l taffeted texture. More specifically, the invention relates to a shoe-wiping mat with color pattern for rent, having vivid color pattern, excellent softness, dust-adsorbing property and dust-holding property, preventing undulation phenomenon on the mat surface even after used repetitively, and having excellent fitness to the floor surfaces.
(Description of the Prior Art) Dust-control (shoe-wiping) mats have heretofore been widely used for preventing outdoor dust and dirt from entering into indoors adhering to the bottoms of the shoes. The dust-control mats are used on a rental basis; i.e., the mats are rented to a customer for a predetermined period of time, laid on a place such as porch through where people go in and out, recovered, washed, regenerated by the treatment with an oil or the like, and are rented again to the customers.
The rental mats include those of the separate type in which a mat with piles is detachably attached to a rubber frame-like base as disclosed in Japanese Patent Publication No. 7450/1984 and those of the unitary type in which a rubber sheet is fastened to the back side of the piled mat as disclosed in Japanese Patent Publication No. 7 213/1992. The latter mats, however, are now preferred owing to their stability when they are laid and appearance.
The shoe-wiping mats are used being laid on entrances of shops, hotels and offices. It has therefore been desired to provide shoe-wiping mats that draw attention and are fashionable, and there have been used shoe-wiping mats having color patterns using taffeta piles of a plurality of hues as taffeta.
The shoe-wiping mats with color pattern for rent have heretofore been produced by using taffeta piles of a plurality of hues and taffeting the base fabric by using such a device as MOQU~ or WILTON. Of the plurality of colored pile yarns, those pile yarns that do not appear as piles on the surface necessarily exist as dead yarns.
Therefore, the pile yarns are used wastefully, resulting in an increase in the cost of the mat and in the weight of the mat.
What is more important is that in the mats of this type in which dead yarns exist on the back surface (stitch surface) of the base fabric, the back surface becomes rugged to a conspicuous degree impairing smoothness. Besides, if it is attempted to improve fitness to the floor surface, the thickness of the backing of the elastomer must be increased.
Moreover, since the back surface of the base fabric has a nonhomogeneous texture and structure, the shoe-wiping mat with color pattern for rent is distorted and is undulated after it is used, washed and is regenerated repetitively. That is, the rental mat loses its comm~rcial value, comfort foL
walking on it and dust-removing property.
That is, it would appear that the undulation disappears when the adhesion between the base fabric and the rubber is reinforced. In fact, 21582~1 however, the taffeted base fabric and th@ rubber sheet have radically different chemical compositions and physical properties. There f OEe, ~;mpnsional difference easily occurs during the production, use or regeneration, and any inhomogeneity in the taffeted base fabric becomes a cause of undulation.
For instance, when the rubber she@t is heat melt-adhered to the base fabric of mat, the rubber sheet is elongated by the heat and then undergoes the contraction by the amount by which it is elongated after the production. Accordingly, a ~;mpnsional difference occurs between the two and turns out to be undulation. When washed, furthermore, the rubber does not contract but the base fabric contracts to develop a ~;mensional difference which is a cause of undulation. The ~;m~nsional difference similarly occurs even under the conditions in which it is used where the heat, light, vapor and water are acting thereto.
SUMMARY OF THE INVENTION
The object of the present invention therefore is to provide a shoe-wiping mat with color pattern for rent, having a novel taffeted texture and, particularly, to provide a shoe-wiping mat with color pattern for rent, having vivid color pattern, excellent softness, dust-adsorbing property and dust-holding property, preventing undulation phenomenon on the mat surface even after it is used repetitively, and having excellent fitness to the floor surfaces.
According to the present invention, there is provided a shoe-wiping mat for rent comprising a base fabric, mat piles taffeted to the base fabric, and an elastomer backing applied to the non-pile surface of the base fabric, wherein a row of taffeta stitches in the direetion of widih ~f the base fabric is slightly tilted relative to the direetion of width of the base fabric and is form~d in a zig-zag shape from a folding point Qrl on@ side to a folding point on the other side maintaining a predetermined distance in the direetion of width and a small distance in the lengthwise direction, thereby to form a belt-like row of taffeta stitches which as a whole extends in the lengthwise direetion of the base fabric, boundary lines connecting the folding points which ar@ neighboring in the lengthwise direetion of taffeta stitches ar@
formed in a zig-zag shape having a pitch greater than the pitch between said folding points, the folding points of the belt-like row of taffeta stitches neighboring in the direetion of width of the base fabric are positioned on common zig-zag boundary lines, the folding points of the belt-like row of one side are positioned at the centers of the folding points which are neighboring in the lengthwise direetion of the belt-like row of the other side, mat piles have a plurality of mat pile surfaces of different hues, the mat piles do not at all have dead yarns, and at least one unstitched portion exists between the neighboring mat pile surfaces of different hues.
In the shoe-wiping mat of the present invention, it is desired that the rows of taffeta stitches that are neighboring in the lengthwise direetion are so formed as to have different sizes in order to form zig-zag boundary lines, and that an average width (W) between the folding points of taffeta stitches in the direction of width of the base fabric is from 10 to 200 mm and, partieularly, 215~2~1 from 2~ to 80 mm, that the pitch (Ps) b@tween th@
folding points in the lengthwise direct~o~ is fEom 1 to 30 mm and, particularly, from 3 to ~ ~m, and that the size of deviation (Ws) in the direction of width is from 1 to 40 mm and, particularly, from 2 to 16 mm. It is further desired that the size of protrusion (Z) of the zig-zag boundary lines in the direction of width of the base fabric is rom 1 to 40 mm and, particularly, from 5 to 25 mm, and the pitch in the lengthwise direction (Pz) is from 10 to 100 mm and, particularly, from 20 to 80 mm.
The shoe-wiping mat with color pattern for rent of the present invention comprises the base fabric, mat piles taffeted to the base fabric, and the elastomer backing applied to the non-pile surface of the base fabric, and a first feature resides in the double rows of taffeta stitches of the base fabric, that are forming a particular zig-zag structure.
That is, in the mat of the present invention, a row of taffeta stitches is slightly tilted relative to the direction of width of the base fabric and is formed in a relatively small zig-zag shape from a folding point on one side to a folding point on the other side maintaining a predetermined distance in the direction of width and a small distance in the lengthwise direction, thereby to form a belt-like row of taffeta stitches which as a whole extends in the lengthwise direction of the base fabric, and boundary lines connecting the folding points which are neighboring in the lengthwise direction of taffeta stitches are formed in a zig-zag shape having a pitch greater than the pitch between said folding points creating the double zig-zag structure.
'241 To explain the arra~ge~nt and ~ize of the double zig~zag st ucture of ta~f@ta stitche& of the present invention, Fig. 3 illustrates a basic recurring unit of the rows of taffeta stitches, and wherein X represents the direction of width and Y
represents the lengthwise direction.
First, the stitches consist of unit rows lOa and lOb which are con~inuous in series mai~taining a small distance. The unit row lOa(lOb) is slightly tilted in the direction X of width of the base fabric, and is formed in a zig-zag shape from a folding point lla(12a) on one side to a folding point 12a(12b) on the o~her side maintaining a predetermined distance (W~Ws/2; W is an aveEage size in the direction of width and Ws is a size of deviation of small zig-zag shape in the direction of width) in the direction X of width and maintaining a small distance (Ps/2; Ps is a pitch of small zig-zag shape in the lengthwise direction) in the lengthwise direction, forming a belt-like row 13A of taffeta stitches which, as a whole, extends in the lengthwise direction of the base fabric.
Boundary lines 14(15) connecti~g the neighboring folding points lla, llb, llc, --- (12a, 12b, 12c, ---) of taffeta stitches in the lengthwise direction are forming zig-zag boundary lines having a pitch Pz in the lengthwise direction which is greater than the pitch Ps between the folding points in the lengthwise direction and having a size of protrusion Z in the direction of width. That is, the unit row lOa of taffeta stitches is longer than the unit row lOb, which gives a size of deviation Ws of a small zig-zag shape and, consequently, gives the pitch Pz of a 2i~241 -large zig-zag shape in the lengthwis@ direetion and the size of protrusion Z in the direction of width.
A ~;m~nsional relationship of unit rows lOa and lOb of taffeta stitches is inverted at given folding points. The inverting positions, i.e., the folding positions of the large zig-zag shape 14 are n-th positions as counted from the staLt point, where n is a number satisfying the following formulas (1) and (2), n = Z/Ws --- (1) n = Pz/2Ps --- (2) In the embo~;m~nt shown in Fig. 3, the olding point lld corresponds thereto.
The belt-like row 13A of taffeta stitches is formed in a side-by-side relationship in the direction X of base fabric relative to the right and left neighboring belt-like rows 13B and 13C, the folding points of the belt-like rows 13B, 13C
of taffeta stitches which are neighboring in the direction X of width of the base fabric are positioned on the common zig-zag boundary lines 14, 15, and the folding points 16a, 16b, --- (17a, 17b, ---) of the belt-like rows 13B(13C) of the neighboring sides are positioned at the centers of the neighboring folding points lla, llb, --- (12a, 12b, ---) in the lengthwise direction of the belt-like row 13A of the side that serves as a reference. That is, the belt-like rows 13A, 13B, 13C of taffeta stitches which are neighboring in the direction X of width of the base fabric are in phase in regard to the pitch Pz of the large zig-zag shape but are out of phase by 1/2 in regard to the pitch Ps of the small zig-zag shape.
According to the present invention which employs the above-mentioned taffeta stitch texture, the mat is prevented from being deviated when it is laid on the floor and is, further, effectlvely prevented from developing undulation when it is used, washed and is regenerated repetitively.
The deviation in position of the mat wh~ch ~
a problem in the present invention is a phenomenon in which when people walk treading on the mat laid on the inlet, the mat is slightly deviated in position from where it is laid on the floor surface due to the pressure of when it is trod and the release of pressure. This stems from the fact that the mat piles that are implanted have a directivity. To eliminate such a positional deviation, therefore, it is important to @liminate the directivity of implantation.
The mat of the present invention has taffeta stitches that constitute two large and small zig-zag structures in the lengthwise direction of the base fabric of the mat and, further, constitute wedge-like structure in both directions in the direction of width of the base fabric of the mat.
Due to the zig-zag structures and wedge-like structure of the taffeta stitches, therefore, there is obtained a restoring force which prevents the mat from moving in any direction, and the mat is prevented from being deviated in position.
In addition to the combination of the zig-zag structures and wedge-like structure of the taffeta stitches, furthermore, the folding points of the belt-like rows of taffeta stitches that are neighboring in the direction of width of the base fabric are positioned on the common zig-zag boundary lines, and the folding points of the belt-like row on one side are located at the centers of the folding points that are neighboring in the ~5~
lengthwise diEec~on of ~he ~el~ like row of th@
oth@r side, whe~eby the ~affetA stlt~hes exi~t ~n a random fashion and uniformly as a whole, the residual stress is disper~ed when the mat is used, washed and regenera~@d r@pe~itively, and occurlenee of undulation is effect vely prevented.
In the shoe-wiping mat of the pLe~ent invention, the mat piles hav@ a plurality of mat pile surfaces of different hues to impart it~ own ornamental effect and fashionableness. Here, a distinguished feature resides in that the mat piles do not at all have dead yarns, and at least one unstitched portion exis~s between th~ neighboring mat pile surace of dif@rent hues.
That is, at least one unstitched portion is present be~ween the neighboring mat pil@ surfaces of different hues, making it possible to effectively prevent the mat piles of different hues from m; 2i ng in the boundary portion of the mat pile surfaces and, hence, to form a vivid and C1eaE
pattern on the surface of the mat.
In the shoe-wiping mat of the present invention having a multi-color pattern, furthermore, the mat pil-es ~-not i~clude any dead yarn; i.e., the yarns are all used for forming the mat piles. It is therefore made possible to save the amount of the yarns and to uniformalize the texture of mat piles on the upper surface of the base fabric, presenting distinguished effects from the standpoint of softness and the feel of the piles, dust-adsorbing property and dust-holding property, and preventing undulation.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a sectional view which schematically illustrates a shoe-wiping mat with color pattern 215~241 :,~
~r rent ~ E~ en~
~ p~ v-~w i~ L~ing, ~ a~
enlarged scale, the stitched surface of the base fabric of the shoe-wiping mat of the present invention;
Fig. 3 is a diagr~m explai~ing ~he arrangem@nt and size of a double ~ig-zag stru~ture of taffeta stitch@s acc~rding to th@ present invention; and Fig. 4 is a diagram illustrating the structure of taffeta stitches of a sample B used in the example.
DETAILED DESCRI~TION OF THE INVENTION
Fig. 1 is a sectional view which schematically illustrates the shoe-wiping mat with color patt@rn for rent according to the present invention, and Fig. 2 is a plan view illus~rating, on an enlarged scale, the stitched surface of a base fabric of the mat.
The shoe-wiping mat with color pattern for rent of the present invention comprises a base fabric 1, mat piles 2 taffeted on the base fabric, and an elastomer backing 3 applied to ~he non-pile surface of the base fabric. Taffeta stitches 4 exist on the back surface of the base fabric 1.
Pile patterns 5a, 5b, 5c, --- having different hues exist on the mat pile surface of the shoe-wiping mat. At least one unstitched portion 6 exists in the boundary of the pile patterns.
According to the present invention, the mat piles 2 are all taffeted to the base fabric 1 at a predetermined driving density, and there exist no dead yarn or yarn that extends in parallel with the base fabric in excess of a predetermined stitch length.
The basic pattern (taffeta stitch texture) of 215~ql th@ row of taffeta stitehes 4 of ~iqO 2 was descrlbed in detail with reference to ~ig. 3, and it should be noted that the unstitched portion 6 exists between the pil@ patterns of diferent hues not only in the direction of width of the base fabric but also in the leng~hwis@ direGtion of the base fabric.
In the shoe-wiping mat of the pres@nt invention, it is desired that the average width (W) between the folding points of the rows lOa and lOb of taffeta stitches 4 in the direction of width of the base abric is from 10 to 200 mm and, particularly, from 20 to 80 mm from the standpoint of taffeting the mat piles and of preventing the position deviation and undulation of the mat. From the same point of view and of selecting a proper taffeting density, furthermore, it is desired that the pitch (Ps) between the folding points in the lengthwise direction is from 1 to 30 mm and, particularly, from 3 to 20 mm, and the size of deviation (Ws) in the direction of width is from 1 to 40 mm and, particularly, from 2 to 16 mm.
It is further desired that the~size of protrusion (Z) of the zig-zag boundary line in the direction of width of the base fabric is from 1 to 40 mm and, particularly, from 5 to 25 mm and that the pitch (Pz) in the lengthwise direction is from 10 to 100 mm and, particularly, from 20 to 80 mm from the object of the present invention. When Z
is smaller than the above-mentioned range or when Pz is larger than the above-mentioned range, only small effect is obtained for preventing the position deviation of the mat and for preventing undulation. In the opposite case, taffeting efficiency decreases.
21 5 ~
T~e ~ y m~ ~
is ta~ y ~ p~ u~
patterned and ta~fe~ed prod~ct~ disclosed in Japanese Laid Qpen Patent Publication NQ . 50 14 62/1986 and by controlling the ~af~eted pattern as described above. In thi production appaEatus, yarns having different colors are arbitrarily and selectively fed to the op@ner (taffeting needl@) for the base fabric, a taffeting needle is corresponded to each belt~like row, and the taffeting needle is scanned and the yarns are fed in a controlled manner as descrihed above. This control is easily perform~d by setting a pattern to a control corlE~uter in advance.
As the base fabriG, there can be used woven fabrics and nonwoven fabrics of a variety of fibers. As the woven fabric, there can be used a plain woven fabric or a modified woven fabric obtained by weaving spun yarns or multi-filament yarns. As the nonwoven fabric, on the other hand, there can be used those of the spun-bonded type, melt-blown type or heat melt-adhered type. The base fabric may be comprised of any synthetic fibers such as polyeste~ fibers, polyamide fibers, acryl fibers or ultra-high molecular polyolefin fibers. Most desirably, however, the base fabric should be comprised of a high molecular thermoplastic polyester and, particularly, a thermoplastic copolyester composed chiefly of polyethylene terephthalate or ethylene terephthalate.
It is desired that the weight of the base fabric is, generally, from 50 to 500 g/m2 and, particularly, from 100 to 400 g/m2 though it may vary depending upon the weight of the mat.
21S82~1 ~s ~h~ h~ g ~r~ul~
~x~ell~h~ d~la~n, t~
~a~ s~d ~ ~lai~ n ~ ~ ya~n~
(film yarns) of a dra~n polyester f~m. As the mat piles having excellent erecting property, furthermore, there can be used a base fabEic obtained by needle punching a floss-like s~nthetic fiber to the plain WOV@~ fabric of fla~ slit yarn of the drawn polyes~er film. The flat slit yarns are obtained by slitting a forcibly drawn polyester film having a thickness of from 10 to 5000 ~m to have a width of from about 2 to about 25 mm.
Though the ~bove-mentioned synthetic fibers can be all used as the floss~like synthetic fibers, it is desired to use the polyester fibers. The floss D~
like fibers are obtained by superposing a fiber web formed by carding or ~he like on both sides of the woven fabric, and causing the fibers to be entangled by one another. The single fiber may have a thickness of from about 1 to about 20 deniers.
As the pile yarns to be driven into the base fabric, there can be used spun yarns or multi-filament yarns consisting of one or two or more kinds of cotton fibersj -rayon fibers, polyvinyl alcohol fibers, acryl fibers, nylon fibers and any other synthetic fibers. It is desired that the mat piles are multi-filament yarns or spun yarns of nylon fibers or acryl fibers. The pile yarns can be implanted, i.e., taffeted by the above-mentioned means. Moreover, the mat pile yarns may be curled or uncurled, and the pile length may be the same or different.
Generally, it is desired that the mat pile yarns have a thickness of from 300 to 10000 deniers/yarn and, particularly, from ~0~ to ~
deniers/yarn, has a number of twists Qf fEOm ~ to 500 turns/m and, particularly, from 1~ to 3~
turns/m, and have a pile length of from 3 to 20 mm and, particularly, from 5 to 15 mm. It is further desired that the mat piles are driven into th@ base fabric in a number of from 3 to 20 pi~e /inch and, particularly, from 5 to 14 piles/inch.
The shoe-wiping mat of the present invention can be adapted to either a unitary mat that does not require any particular underlay (base) or to a separate mat that requires the underlay. In the former case, the rubber sheet is formed together with the base fabric to form a backing and in the latter case, a rubber latex is applied to form a thin rubber backing layer.
As the rubber that serves as the backing, there can be used a variety of elastomer polymers such as nitrile-butadiene rubber (NBR), styrene-butadiene rubber (SBR), chloroprene rubber (~R),polybutadiene (BR), polyisoprene (IIB), butyl rubber, natural rubber, ethylene-propylene rubber (EPR), ethylene-propylene-diene rubber ( EPDM), polyurethane, chlorinated polyethylene, chlorinated polypropylene, soft vinyl chloride resin and the like. From the standpoint of resistance against oils and weatherability, it is desired to use the nitrile-butadiene rubber (NBR). In forming the rubber backing, it is allowed to blend widely known blending agents such as sulfur or organic curing agent, cure promoting agent, softening agent, anti-aging agent, filler, dispersant, plasticizer, coloring agent and the like agents in known amounts.
In forming a mat as a unitary structure, the 2~582 11 composition is then ri~lded into a sh~et an~ o~
which is then placed a taffeted mat. The laminate is then heat~d and p~eSSULiZed ~n a pressurizing mold to effect the adh@sion and cuEing simultaneously. To increase the adhesion be~ween the rubbex sheet ~nd th@ base abriG, th@ non pile surface of the base fabric may be coated with a rubber latex of the same kind as the rubber sheet.
Or, an adhesive agent such as an ethylene acet ate/vinyl copol~mer or an adhesion promoting agent may be applied thereto in advance. It is desired that the weight of the r~bber sheet lies within a range of from 100 to 3200 g/m2, and the rubher sheet and the base fabric are adhered together as a unitary structure in such a manner that the edges of the rubber sheet slightly protrude outwardly beyond the edges of the base fabric. The adhesion by curing is better carried out at a temperature of from 90 to 200 C under a pressure of from 0.5 to 10 kg/cm2.
When a soft vinyl chloride resin is used as the rubber sheet, a plastic sol of t~he vinyl chloride resin is applied to the non pile surface of the pile-implanted base fabric and, then, the plastic sol layer of the vinyl chloride resin is gelled upon heating. When a polyurethane is used as the rubber sheet, a two-can type polyurethane resin composition is applied to the non-pile surface of the pile-implanted base fabric and is then cured upon hea~ing or the like.
The backing of the separate mat is formed by applying a latex of the above-mentioned elastomer followed by drying or curing. The curing can be ~15~2~1 effected under normal pressure at the abov@~m@ntion ed temperature.
It is desired that the elastomer backing has a thickness of, generally, from 0.01 mm to 3 mm and, particularly, from 0.1 to 2.5 mm. When the thickness is relatively as small as 0.5 ~n or le5s, the elastomer backing can be used in combination with the mat base. When the thicknes 5 is not smaller than 0.5 mm, the elastomer backing can be used by itself as a unitary mat.
The pile yarns of the mat of the present invention adsorb and hold dust adhered to t~e bottoms of the shoes. To further enhance this action, the pile yarns may be coated or im~regnated with a dust-adsorbing oil. As the dust-adsorbing liquid, there can be used mineral oils such as fluidized paraffin, spindle oil, alkylbenzene oi1, diester oil and castor oil, or such oils as synthetic oils or plant oils, or aqueous dust-adsorbing agent as disclosed in Japanese Patent Publications Nos. 1019/1978 and 37471/1978.
Usually, the adsorbing agent may be applied in an amount of from 0.1 to 200 g/m2.
EXAMPLES
The invention will now be described in further detail by way of the following Examples.
(Example 1) BCF nylon: 9 stitches/inch gauge 1/10 pile length 9 mm weight 1700 g/m2 cut pile Base fabric: polyester plain woven fabric 150 g/m2 *polyester cotton 100 g/m2 Tot:al 250 g/Ig~2 The polyester cotton was punch-worked using a 21S~41 needle.
Th~ ~m~ A a~ E~ E~ @
followiAg driving design.
The samples A and B were so set as to have the same nUmbeE o taffetas/inch.
S~mple A: linear taffetas Sample B: shown Ln ~ig~ 4 The above mentioned 5taLting fabric was coated with the latex followed by drying at 175 C for 15 minutes, and was cured together with an uncured rubber sheet that was cut into a size of 70 x 85 cm having a thickness of 1.8 mm under the conditions of a temperature of 170 C for 15 minu~e under a pressure of 5 kg/cm2.
The mat was laid for three days on a place where 3000 people walk through a day and was then washed. This was repeated 40 times to measure the degree of contraction of the mat and the occurrence of undulation.
Table 1 Item A B
25 Lengthwise Coefficient contracted direction of contraction by 2.8% 1.3%
Undulation 10 mm x 5 0 30 Direction Coefficient contracted of width of contraction by 1.4% 1.4%
Undulation 10 mm x 4 0 21~2gl As is obvious from Table 1, the sam~le A
having a linear weaving direction is greatly contracted in the lengthwise direction and the mat as a whole undulated. On the other hand, the sample B uniformly contracted in both the dir@ction of width and lengthwise direction, and was neith@r locally contracted nor undulated, and cou~d be favorably used.
According to the present invention which employs a particular taffeta stitch texture of a double zig-zag structure, it is allowed to prevent the positional deviation of the mat that is used being laid on the floor, and occurrence of undulation is effectively prevented even when the mat is used, washed and regenerated repetitively.
That is, in the taffeta-stitched mat of the present invention, there exist two large and small zig-zag structures in the lengthwise direction of the base fabric of the mat, and the wedge-like structure exists in both directions in the direction of width of the base fabric of the mat.
Due to the zig-zag structure and wedge~like structure of taffeta stitches, therefore, there is obtained a restoring force that prevents the mat from moving in any direction, and the mat is prevented from being deviated in position.
In addition to the combination of the zig-zag structure and the wedge-like structure of taffeta stitches, furthermore, the folding points of the belt-like row of taffeta stitches neighboring in the direction of width of the base fabric are positioned on common zig-zag boundary lines, and the folding points of the belt-like row of one side are positioned at the centers of the folding point5 which are neighboring in the lengthwise direction 2158~Al of the belt-like row of the other side. Therefor@, the taffeta stitches as a whole exist in a random fashion and uniformly, and the residual stress is dispersed when the mat is used, washed and regenerated repetitively, and occurrenc@ o undulation is effectively prevented.
In the shoe-wiping mat of the pres@nt invention, furthermore, the mat piles have a plurality of mat pile surfaces of different hues to impart its own ornamental effect and fashionableness. Here, however, the mat piles do not at all include dead yarn, and at least one unstitched portion exists between the neighboring mat pile surfaces having different dues, offering the following distinguished advantages.
That is, with at least one unstitched portion being interposed between the neighboring mat pile surfaces of different hues, the mat piles having different hues are effectively prevented from being mixed in the boundary portion of the mat pile surfaces, and it is allowed to form a vivid and clear pattern on the surface of the mat.
In the shoe-wiping mat having multi-color pattern of the present invention, furthermore, the mat piles do not at all contain dead yarn and the yarns are all used for forming the mat piles, making it possible to save the amount of the yarns, to uniformalize the mat pile texture on the base fabric, and offering distinguished effects in regard to softness and the feel of the piles, dust-adsorbing property, dust-holding property, and preventing undulation.
SHOE-WIPING MAT FOR RENT
BACRGROUND OF THE INVENTION
(Field of the Invention) The present invention relates to a shoe-wiping mat with color pattern for rent, having a nov@l taffeted texture. More specifically, the invention relates to a shoe-wiping mat with color pattern for rent, having vivid color pattern, excellent softness, dust-adsorbing property and dust-holding property, preventing undulation phenomenon on the mat surface even after used repetitively, and having excellent fitness to the floor surfaces.
(Description of the Prior Art) Dust-control (shoe-wiping) mats have heretofore been widely used for preventing outdoor dust and dirt from entering into indoors adhering to the bottoms of the shoes. The dust-control mats are used on a rental basis; i.e., the mats are rented to a customer for a predetermined period of time, laid on a place such as porch through where people go in and out, recovered, washed, regenerated by the treatment with an oil or the like, and are rented again to the customers.
The rental mats include those of the separate type in which a mat with piles is detachably attached to a rubber frame-like base as disclosed in Japanese Patent Publication No. 7450/1984 and those of the unitary type in which a rubber sheet is fastened to the back side of the piled mat as disclosed in Japanese Patent Publication No. 7 213/1992. The latter mats, however, are now preferred owing to their stability when they are laid and appearance.
The shoe-wiping mats are used being laid on entrances of shops, hotels and offices. It has therefore been desired to provide shoe-wiping mats that draw attention and are fashionable, and there have been used shoe-wiping mats having color patterns using taffeta piles of a plurality of hues as taffeta.
The shoe-wiping mats with color pattern for rent have heretofore been produced by using taffeta piles of a plurality of hues and taffeting the base fabric by using such a device as MOQU~ or WILTON. Of the plurality of colored pile yarns, those pile yarns that do not appear as piles on the surface necessarily exist as dead yarns.
Therefore, the pile yarns are used wastefully, resulting in an increase in the cost of the mat and in the weight of the mat.
What is more important is that in the mats of this type in which dead yarns exist on the back surface (stitch surface) of the base fabric, the back surface becomes rugged to a conspicuous degree impairing smoothness. Besides, if it is attempted to improve fitness to the floor surface, the thickness of the backing of the elastomer must be increased.
Moreover, since the back surface of the base fabric has a nonhomogeneous texture and structure, the shoe-wiping mat with color pattern for rent is distorted and is undulated after it is used, washed and is regenerated repetitively. That is, the rental mat loses its comm~rcial value, comfort foL
walking on it and dust-removing property.
That is, it would appear that the undulation disappears when the adhesion between the base fabric and the rubber is reinforced. In fact, 21582~1 however, the taffeted base fabric and th@ rubber sheet have radically different chemical compositions and physical properties. There f OEe, ~;mpnsional difference easily occurs during the production, use or regeneration, and any inhomogeneity in the taffeted base fabric becomes a cause of undulation.
For instance, when the rubber she@t is heat melt-adhered to the base fabric of mat, the rubber sheet is elongated by the heat and then undergoes the contraction by the amount by which it is elongated after the production. Accordingly, a ~;mpnsional difference occurs between the two and turns out to be undulation. When washed, furthermore, the rubber does not contract but the base fabric contracts to develop a ~;mensional difference which is a cause of undulation. The ~;m~nsional difference similarly occurs even under the conditions in which it is used where the heat, light, vapor and water are acting thereto.
SUMMARY OF THE INVENTION
The object of the present invention therefore is to provide a shoe-wiping mat with color pattern for rent, having a novel taffeted texture and, particularly, to provide a shoe-wiping mat with color pattern for rent, having vivid color pattern, excellent softness, dust-adsorbing property and dust-holding property, preventing undulation phenomenon on the mat surface even after it is used repetitively, and having excellent fitness to the floor surfaces.
According to the present invention, there is provided a shoe-wiping mat for rent comprising a base fabric, mat piles taffeted to the base fabric, and an elastomer backing applied to the non-pile surface of the base fabric, wherein a row of taffeta stitches in the direetion of widih ~f the base fabric is slightly tilted relative to the direetion of width of the base fabric and is form~d in a zig-zag shape from a folding point Qrl on@ side to a folding point on the other side maintaining a predetermined distance in the direetion of width and a small distance in the lengthwise direction, thereby to form a belt-like row of taffeta stitches which as a whole extends in the lengthwise direetion of the base fabric, boundary lines connecting the folding points which ar@ neighboring in the lengthwise direetion of taffeta stitches ar@
formed in a zig-zag shape having a pitch greater than the pitch between said folding points, the folding points of the belt-like row of taffeta stitches neighboring in the direetion of width of the base fabric are positioned on common zig-zag boundary lines, the folding points of the belt-like row of one side are positioned at the centers of the folding points which are neighboring in the lengthwise direetion of the belt-like row of the other side, mat piles have a plurality of mat pile surfaces of different hues, the mat piles do not at all have dead yarns, and at least one unstitched portion exists between the neighboring mat pile surfaces of different hues.
In the shoe-wiping mat of the present invention, it is desired that the rows of taffeta stitches that are neighboring in the lengthwise direetion are so formed as to have different sizes in order to form zig-zag boundary lines, and that an average width (W) between the folding points of taffeta stitches in the direction of width of the base fabric is from 10 to 200 mm and, partieularly, 215~2~1 from 2~ to 80 mm, that the pitch (Ps) b@tween th@
folding points in the lengthwise direct~o~ is fEom 1 to 30 mm and, particularly, from 3 to ~ ~m, and that the size of deviation (Ws) in the direction of width is from 1 to 40 mm and, particularly, from 2 to 16 mm. It is further desired that the size of protrusion (Z) of the zig-zag boundary lines in the direction of width of the base fabric is rom 1 to 40 mm and, particularly, from 5 to 25 mm, and the pitch in the lengthwise direction (Pz) is from 10 to 100 mm and, particularly, from 20 to 80 mm.
The shoe-wiping mat with color pattern for rent of the present invention comprises the base fabric, mat piles taffeted to the base fabric, and the elastomer backing applied to the non-pile surface of the base fabric, and a first feature resides in the double rows of taffeta stitches of the base fabric, that are forming a particular zig-zag structure.
That is, in the mat of the present invention, a row of taffeta stitches is slightly tilted relative to the direction of width of the base fabric and is formed in a relatively small zig-zag shape from a folding point on one side to a folding point on the other side maintaining a predetermined distance in the direction of width and a small distance in the lengthwise direction, thereby to form a belt-like row of taffeta stitches which as a whole extends in the lengthwise direction of the base fabric, and boundary lines connecting the folding points which are neighboring in the lengthwise direction of taffeta stitches are formed in a zig-zag shape having a pitch greater than the pitch between said folding points creating the double zig-zag structure.
'241 To explain the arra~ge~nt and ~ize of the double zig~zag st ucture of ta~f@ta stitche& of the present invention, Fig. 3 illustrates a basic recurring unit of the rows of taffeta stitches, and wherein X represents the direction of width and Y
represents the lengthwise direction.
First, the stitches consist of unit rows lOa and lOb which are con~inuous in series mai~taining a small distance. The unit row lOa(lOb) is slightly tilted in the direction X of width of the base fabric, and is formed in a zig-zag shape from a folding point lla(12a) on one side to a folding point 12a(12b) on the o~her side maintaining a predetermined distance (W~Ws/2; W is an aveEage size in the direction of width and Ws is a size of deviation of small zig-zag shape in the direction of width) in the direction X of width and maintaining a small distance (Ps/2; Ps is a pitch of small zig-zag shape in the lengthwise direction) in the lengthwise direction, forming a belt-like row 13A of taffeta stitches which, as a whole, extends in the lengthwise direction of the base fabric.
Boundary lines 14(15) connecti~g the neighboring folding points lla, llb, llc, --- (12a, 12b, 12c, ---) of taffeta stitches in the lengthwise direction are forming zig-zag boundary lines having a pitch Pz in the lengthwise direction which is greater than the pitch Ps between the folding points in the lengthwise direction and having a size of protrusion Z in the direction of width. That is, the unit row lOa of taffeta stitches is longer than the unit row lOb, which gives a size of deviation Ws of a small zig-zag shape and, consequently, gives the pitch Pz of a 2i~241 -large zig-zag shape in the lengthwis@ direetion and the size of protrusion Z in the direction of width.
A ~;m~nsional relationship of unit rows lOa and lOb of taffeta stitches is inverted at given folding points. The inverting positions, i.e., the folding positions of the large zig-zag shape 14 are n-th positions as counted from the staLt point, where n is a number satisfying the following formulas (1) and (2), n = Z/Ws --- (1) n = Pz/2Ps --- (2) In the embo~;m~nt shown in Fig. 3, the olding point lld corresponds thereto.
The belt-like row 13A of taffeta stitches is formed in a side-by-side relationship in the direction X of base fabric relative to the right and left neighboring belt-like rows 13B and 13C, the folding points of the belt-like rows 13B, 13C
of taffeta stitches which are neighboring in the direction X of width of the base fabric are positioned on the common zig-zag boundary lines 14, 15, and the folding points 16a, 16b, --- (17a, 17b, ---) of the belt-like rows 13B(13C) of the neighboring sides are positioned at the centers of the neighboring folding points lla, llb, --- (12a, 12b, ---) in the lengthwise direction of the belt-like row 13A of the side that serves as a reference. That is, the belt-like rows 13A, 13B, 13C of taffeta stitches which are neighboring in the direction X of width of the base fabric are in phase in regard to the pitch Pz of the large zig-zag shape but are out of phase by 1/2 in regard to the pitch Ps of the small zig-zag shape.
According to the present invention which employs the above-mentioned taffeta stitch texture, the mat is prevented from being deviated when it is laid on the floor and is, further, effectlvely prevented from developing undulation when it is used, washed and is regenerated repetitively.
The deviation in position of the mat wh~ch ~
a problem in the present invention is a phenomenon in which when people walk treading on the mat laid on the inlet, the mat is slightly deviated in position from where it is laid on the floor surface due to the pressure of when it is trod and the release of pressure. This stems from the fact that the mat piles that are implanted have a directivity. To eliminate such a positional deviation, therefore, it is important to @liminate the directivity of implantation.
The mat of the present invention has taffeta stitches that constitute two large and small zig-zag structures in the lengthwise direction of the base fabric of the mat and, further, constitute wedge-like structure in both directions in the direction of width of the base fabric of the mat.
Due to the zig-zag structures and wedge-like structure of the taffeta stitches, therefore, there is obtained a restoring force which prevents the mat from moving in any direction, and the mat is prevented from being deviated in position.
In addition to the combination of the zig-zag structures and wedge-like structure of the taffeta stitches, furthermore, the folding points of the belt-like rows of taffeta stitches that are neighboring in the direction of width of the base fabric are positioned on the common zig-zag boundary lines, and the folding points of the belt-like row on one side are located at the centers of the folding points that are neighboring in the ~5~
lengthwise diEec~on of ~he ~el~ like row of th@
oth@r side, whe~eby the ~affetA stlt~hes exi~t ~n a random fashion and uniformly as a whole, the residual stress is disper~ed when the mat is used, washed and regenera~@d r@pe~itively, and occurlenee of undulation is effect vely prevented.
In the shoe-wiping mat of the pLe~ent invention, the mat piles hav@ a plurality of mat pile surfaces of different hues to impart it~ own ornamental effect and fashionableness. Here, a distinguished feature resides in that the mat piles do not at all have dead yarns, and at least one unstitched portion exis~s between th~ neighboring mat pile surace of dif@rent hues.
That is, at least one unstitched portion is present be~ween the neighboring mat pil@ surfaces of different hues, making it possible to effectively prevent the mat piles of different hues from m; 2i ng in the boundary portion of the mat pile surfaces and, hence, to form a vivid and C1eaE
pattern on the surface of the mat.
In the shoe-wiping mat of the present invention having a multi-color pattern, furthermore, the mat pil-es ~-not i~clude any dead yarn; i.e., the yarns are all used for forming the mat piles. It is therefore made possible to save the amount of the yarns and to uniformalize the texture of mat piles on the upper surface of the base fabric, presenting distinguished effects from the standpoint of softness and the feel of the piles, dust-adsorbing property and dust-holding property, and preventing undulation.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a sectional view which schematically illustrates a shoe-wiping mat with color pattern 215~241 :,~
~r rent ~ E~ en~
~ p~ v-~w i~ L~ing, ~ a~
enlarged scale, the stitched surface of the base fabric of the shoe-wiping mat of the present invention;
Fig. 3 is a diagr~m explai~ing ~he arrangem@nt and size of a double ~ig-zag stru~ture of taffeta stitch@s acc~rding to th@ present invention; and Fig. 4 is a diagram illustrating the structure of taffeta stitches of a sample B used in the example.
DETAILED DESCRI~TION OF THE INVENTION
Fig. 1 is a sectional view which schematically illustrates the shoe-wiping mat with color patt@rn for rent according to the present invention, and Fig. 2 is a plan view illus~rating, on an enlarged scale, the stitched surface of a base fabric of the mat.
The shoe-wiping mat with color pattern for rent of the present invention comprises a base fabric 1, mat piles 2 taffeted on the base fabric, and an elastomer backing 3 applied to ~he non-pile surface of the base fabric. Taffeta stitches 4 exist on the back surface of the base fabric 1.
Pile patterns 5a, 5b, 5c, --- having different hues exist on the mat pile surface of the shoe-wiping mat. At least one unstitched portion 6 exists in the boundary of the pile patterns.
According to the present invention, the mat piles 2 are all taffeted to the base fabric 1 at a predetermined driving density, and there exist no dead yarn or yarn that extends in parallel with the base fabric in excess of a predetermined stitch length.
The basic pattern (taffeta stitch texture) of 215~ql th@ row of taffeta stitehes 4 of ~iqO 2 was descrlbed in detail with reference to ~ig. 3, and it should be noted that the unstitched portion 6 exists between the pil@ patterns of diferent hues not only in the direction of width of the base fabric but also in the leng~hwis@ direGtion of the base fabric.
In the shoe-wiping mat of the pres@nt invention, it is desired that the average width (W) between the folding points of the rows lOa and lOb of taffeta stitches 4 in the direction of width of the base abric is from 10 to 200 mm and, particularly, from 20 to 80 mm from the standpoint of taffeting the mat piles and of preventing the position deviation and undulation of the mat. From the same point of view and of selecting a proper taffeting density, furthermore, it is desired that the pitch (Ps) between the folding points in the lengthwise direction is from 1 to 30 mm and, particularly, from 3 to 20 mm, and the size of deviation (Ws) in the direction of width is from 1 to 40 mm and, particularly, from 2 to 16 mm.
It is further desired that the~size of protrusion (Z) of the zig-zag boundary line in the direction of width of the base fabric is from 1 to 40 mm and, particularly, from 5 to 25 mm and that the pitch (Pz) in the lengthwise direction is from 10 to 100 mm and, particularly, from 20 to 80 mm from the object of the present invention. When Z
is smaller than the above-mentioned range or when Pz is larger than the above-mentioned range, only small effect is obtained for preventing the position deviation of the mat and for preventing undulation. In the opposite case, taffeting efficiency decreases.
21 5 ~
T~e ~ y m~ ~
is ta~ y ~ p~ u~
patterned and ta~fe~ed prod~ct~ disclosed in Japanese Laid Qpen Patent Publication NQ . 50 14 62/1986 and by controlling the ~af~eted pattern as described above. In thi production appaEatus, yarns having different colors are arbitrarily and selectively fed to the op@ner (taffeting needl@) for the base fabric, a taffeting needle is corresponded to each belt~like row, and the taffeting needle is scanned and the yarns are fed in a controlled manner as descrihed above. This control is easily perform~d by setting a pattern to a control corlE~uter in advance.
As the base fabriG, there can be used woven fabrics and nonwoven fabrics of a variety of fibers. As the woven fabric, there can be used a plain woven fabric or a modified woven fabric obtained by weaving spun yarns or multi-filament yarns. As the nonwoven fabric, on the other hand, there can be used those of the spun-bonded type, melt-blown type or heat melt-adhered type. The base fabric may be comprised of any synthetic fibers such as polyeste~ fibers, polyamide fibers, acryl fibers or ultra-high molecular polyolefin fibers. Most desirably, however, the base fabric should be comprised of a high molecular thermoplastic polyester and, particularly, a thermoplastic copolyester composed chiefly of polyethylene terephthalate or ethylene terephthalate.
It is desired that the weight of the base fabric is, generally, from 50 to 500 g/m2 and, particularly, from 100 to 400 g/m2 though it may vary depending upon the weight of the mat.
21S82~1 ~s ~h~ h~ g ~r~ul~
~x~ell~h~ d~la~n, t~
~a~ s~d ~ ~lai~ n ~ ~ ya~n~
(film yarns) of a dra~n polyester f~m. As the mat piles having excellent erecting property, furthermore, there can be used a base fabEic obtained by needle punching a floss-like s~nthetic fiber to the plain WOV@~ fabric of fla~ slit yarn of the drawn polyes~er film. The flat slit yarns are obtained by slitting a forcibly drawn polyester film having a thickness of from 10 to 5000 ~m to have a width of from about 2 to about 25 mm.
Though the ~bove-mentioned synthetic fibers can be all used as the floss~like synthetic fibers, it is desired to use the polyester fibers. The floss D~
like fibers are obtained by superposing a fiber web formed by carding or ~he like on both sides of the woven fabric, and causing the fibers to be entangled by one another. The single fiber may have a thickness of from about 1 to about 20 deniers.
As the pile yarns to be driven into the base fabric, there can be used spun yarns or multi-filament yarns consisting of one or two or more kinds of cotton fibersj -rayon fibers, polyvinyl alcohol fibers, acryl fibers, nylon fibers and any other synthetic fibers. It is desired that the mat piles are multi-filament yarns or spun yarns of nylon fibers or acryl fibers. The pile yarns can be implanted, i.e., taffeted by the above-mentioned means. Moreover, the mat pile yarns may be curled or uncurled, and the pile length may be the same or different.
Generally, it is desired that the mat pile yarns have a thickness of from 300 to 10000 deniers/yarn and, particularly, from ~0~ to ~
deniers/yarn, has a number of twists Qf fEOm ~ to 500 turns/m and, particularly, from 1~ to 3~
turns/m, and have a pile length of from 3 to 20 mm and, particularly, from 5 to 15 mm. It is further desired that the mat piles are driven into th@ base fabric in a number of from 3 to 20 pi~e /inch and, particularly, from 5 to 14 piles/inch.
The shoe-wiping mat of the present invention can be adapted to either a unitary mat that does not require any particular underlay (base) or to a separate mat that requires the underlay. In the former case, the rubber sheet is formed together with the base fabric to form a backing and in the latter case, a rubber latex is applied to form a thin rubber backing layer.
As the rubber that serves as the backing, there can be used a variety of elastomer polymers such as nitrile-butadiene rubber (NBR), styrene-butadiene rubber (SBR), chloroprene rubber (~R),polybutadiene (BR), polyisoprene (IIB), butyl rubber, natural rubber, ethylene-propylene rubber (EPR), ethylene-propylene-diene rubber ( EPDM), polyurethane, chlorinated polyethylene, chlorinated polypropylene, soft vinyl chloride resin and the like. From the standpoint of resistance against oils and weatherability, it is desired to use the nitrile-butadiene rubber (NBR). In forming the rubber backing, it is allowed to blend widely known blending agents such as sulfur or organic curing agent, cure promoting agent, softening agent, anti-aging agent, filler, dispersant, plasticizer, coloring agent and the like agents in known amounts.
In forming a mat as a unitary structure, the 2~582 11 composition is then ri~lded into a sh~et an~ o~
which is then placed a taffeted mat. The laminate is then heat~d and p~eSSULiZed ~n a pressurizing mold to effect the adh@sion and cuEing simultaneously. To increase the adhesion be~ween the rubbex sheet ~nd th@ base abriG, th@ non pile surface of the base fabric may be coated with a rubber latex of the same kind as the rubber sheet.
Or, an adhesive agent such as an ethylene acet ate/vinyl copol~mer or an adhesion promoting agent may be applied thereto in advance. It is desired that the weight of the r~bber sheet lies within a range of from 100 to 3200 g/m2, and the rubher sheet and the base fabric are adhered together as a unitary structure in such a manner that the edges of the rubber sheet slightly protrude outwardly beyond the edges of the base fabric. The adhesion by curing is better carried out at a temperature of from 90 to 200 C under a pressure of from 0.5 to 10 kg/cm2.
When a soft vinyl chloride resin is used as the rubber sheet, a plastic sol of t~he vinyl chloride resin is applied to the non pile surface of the pile-implanted base fabric and, then, the plastic sol layer of the vinyl chloride resin is gelled upon heating. When a polyurethane is used as the rubber sheet, a two-can type polyurethane resin composition is applied to the non-pile surface of the pile-implanted base fabric and is then cured upon hea~ing or the like.
The backing of the separate mat is formed by applying a latex of the above-mentioned elastomer followed by drying or curing. The curing can be ~15~2~1 effected under normal pressure at the abov@~m@ntion ed temperature.
It is desired that the elastomer backing has a thickness of, generally, from 0.01 mm to 3 mm and, particularly, from 0.1 to 2.5 mm. When the thickness is relatively as small as 0.5 ~n or le5s, the elastomer backing can be used in combination with the mat base. When the thicknes 5 is not smaller than 0.5 mm, the elastomer backing can be used by itself as a unitary mat.
The pile yarns of the mat of the present invention adsorb and hold dust adhered to t~e bottoms of the shoes. To further enhance this action, the pile yarns may be coated or im~regnated with a dust-adsorbing oil. As the dust-adsorbing liquid, there can be used mineral oils such as fluidized paraffin, spindle oil, alkylbenzene oi1, diester oil and castor oil, or such oils as synthetic oils or plant oils, or aqueous dust-adsorbing agent as disclosed in Japanese Patent Publications Nos. 1019/1978 and 37471/1978.
Usually, the adsorbing agent may be applied in an amount of from 0.1 to 200 g/m2.
EXAMPLES
The invention will now be described in further detail by way of the following Examples.
(Example 1) BCF nylon: 9 stitches/inch gauge 1/10 pile length 9 mm weight 1700 g/m2 cut pile Base fabric: polyester plain woven fabric 150 g/m2 *polyester cotton 100 g/m2 Tot:al 250 g/Ig~2 The polyester cotton was punch-worked using a 21S~41 needle.
Th~ ~m~ A a~ E~ E~ @
followiAg driving design.
The samples A and B were so set as to have the same nUmbeE o taffetas/inch.
S~mple A: linear taffetas Sample B: shown Ln ~ig~ 4 The above mentioned 5taLting fabric was coated with the latex followed by drying at 175 C for 15 minutes, and was cured together with an uncured rubber sheet that was cut into a size of 70 x 85 cm having a thickness of 1.8 mm under the conditions of a temperature of 170 C for 15 minu~e under a pressure of 5 kg/cm2.
The mat was laid for three days on a place where 3000 people walk through a day and was then washed. This was repeated 40 times to measure the degree of contraction of the mat and the occurrence of undulation.
Table 1 Item A B
25 Lengthwise Coefficient contracted direction of contraction by 2.8% 1.3%
Undulation 10 mm x 5 0 30 Direction Coefficient contracted of width of contraction by 1.4% 1.4%
Undulation 10 mm x 4 0 21~2gl As is obvious from Table 1, the sam~le A
having a linear weaving direction is greatly contracted in the lengthwise direction and the mat as a whole undulated. On the other hand, the sample B uniformly contracted in both the dir@ction of width and lengthwise direction, and was neith@r locally contracted nor undulated, and cou~d be favorably used.
According to the present invention which employs a particular taffeta stitch texture of a double zig-zag structure, it is allowed to prevent the positional deviation of the mat that is used being laid on the floor, and occurrence of undulation is effectively prevented even when the mat is used, washed and regenerated repetitively.
That is, in the taffeta-stitched mat of the present invention, there exist two large and small zig-zag structures in the lengthwise direction of the base fabric of the mat, and the wedge-like structure exists in both directions in the direction of width of the base fabric of the mat.
Due to the zig-zag structure and wedge~like structure of taffeta stitches, therefore, there is obtained a restoring force that prevents the mat from moving in any direction, and the mat is prevented from being deviated in position.
In addition to the combination of the zig-zag structure and the wedge-like structure of taffeta stitches, furthermore, the folding points of the belt-like row of taffeta stitches neighboring in the direction of width of the base fabric are positioned on common zig-zag boundary lines, and the folding points of the belt-like row of one side are positioned at the centers of the folding point5 which are neighboring in the lengthwise direction 2158~Al of the belt-like row of the other side. Therefor@, the taffeta stitches as a whole exist in a random fashion and uniformly, and the residual stress is dispersed when the mat is used, washed and regenerated repetitively, and occurrenc@ o undulation is effectively prevented.
In the shoe-wiping mat of the pres@nt invention, furthermore, the mat piles have a plurality of mat pile surfaces of different hues to impart its own ornamental effect and fashionableness. Here, however, the mat piles do not at all include dead yarn, and at least one unstitched portion exists between the neighboring mat pile surfaces having different dues, offering the following distinguished advantages.
That is, with at least one unstitched portion being interposed between the neighboring mat pile surfaces of different hues, the mat piles having different hues are effectively prevented from being mixed in the boundary portion of the mat pile surfaces, and it is allowed to form a vivid and clear pattern on the surface of the mat.
In the shoe-wiping mat having multi-color pattern of the present invention, furthermore, the mat piles do not at all contain dead yarn and the yarns are all used for forming the mat piles, making it possible to save the amount of the yarns, to uniformalize the mat pile texture on the base fabric, and offering distinguished effects in regard to softness and the feel of the piles, dust-adsorbing property, dust-holding property, and preventing undulation.
Claims (8)
1. A shoe-wiping mat for rent comprising a base fabric, mat piles taffeted to the base fabric, and an elastomer backing applied to the non-pile surface of the base fabric, wherein a row of taffeta stitches in the direction of width of the base fabric is slightly tilted relative to the direction of width of the base fabric and is formed in a zig-zag shape from a folding point on one side to a folding point on the other side maintaining a predetermined distance in the direction of width and a small distance in the lengthwise direction, thereby to form a belt-like row of taffeta stitches which as a whole extends in the lengthwise direction of the base fabric, boundary lines connecting the folding points which are neighboring in the lengthwise direction of taffeta stitches are formed in a zig-zag shape having a pitch greater than the pitch between said folding points, the folding points of the belt-like row of taffeta stitches neighboring in the direction of width of the base fabric are positioned on common zig-zag boundary lines, the folding points of the belt- like row of one side are positioned at the centers of the folding points which are neighboring in the lengthwise direction of the belt-like row of the other side, mat piles have a plurality of mat pile surfaces of different hues, the mat piles do not at all have dead yarns, and at least one unstitched portion exists between the neighboring mat pile surfaces of different hues.
2. A shoe-wiping mat according to claim 1, wherein rows of taffeta stitches that are neighboring in the lengthwise direction are so provided as to have sizes which are different from each other.
3. A shoe-wiping mat according to claim 1 or 2, wherein an average width (W) between the folding points of taffeta stitches in the direction of width of the base fabric is from 20 to 80 mm, a pitch (Ps) between the folding points in the lengthwise direction is from 3 to 20 mm, and a size of deviation (Ws) in the direction of width is from 2 to 16 mm.
4. A shoe-wiping mat according to claim 1, 2 or 3, wherein the size of protrusion (Z) of the zig-zag boundary line in the direction of width of the base fabric is from 5 to 25 mm, and a pitch (Pz) in the lengthwise direction is from 20 to 80 mm.
5. A shoe wiping mat according to claim 1, wherein the base fabric comprises a plain woven fabric of flat slit yarns of a drawn polyester film.
6. A shoe wiping mat according to claim 1, wherein the base fabric is obtained by needle-punching a floss-like synthetic fiber to a plain woven fabric of flat slit yarns of a drawn polyester film.
7. A shoe-wiping mat according to claim 1, wherein the mat piles are nylon fibers, multi-filament yarns of acryl fibers or spun yarns, and have a thickness of from 500 to 5000 deniers, a number of twists of 50 to 300 turns per a meter, and a pile length of from 5 to 30 mm.
8. A shoe-wiping mat according to claim 1, wherein the mat piles are driven into the base fabric in a number of 5 to 15 piles per an inch.
Priority Applications (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP6044444A JP2667115B2 (en) | 1994-03-15 | 1994-03-15 | Rental shoe cleaning mat |
| US08/527,136 US5680826A (en) | 1994-03-15 | 1995-09-12 | Shoe-wiping mat for rent |
| EP95306397A EP0763617B1 (en) | 1994-03-15 | 1995-09-13 | Shoe-wiping mat |
| CA002158241A CA2158241A1 (en) | 1994-03-15 | 1995-09-13 | Shoe-wiping mat for rent |
Applications Claiming Priority (5)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP6044444A JP2667115B2 (en) | 1994-03-15 | 1994-03-15 | Rental shoe cleaning mat |
| US08/527,136 US5680826A (en) | 1994-03-15 | 1995-09-12 | Shoe-wiping mat for rent |
| EP95306397A EP0763617B1 (en) | 1994-03-15 | 1995-09-13 | Shoe-wiping mat |
| CA002158241A CA2158241A1 (en) | 1994-03-15 | 1995-09-13 | Shoe-wiping mat for rent |
| AU30613/95A AU712659B2 (en) | 1995-09-14 | 1995-09-14 | Shoe-wiping mat for rent |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2158241A1 true CA2158241A1 (en) | 1997-03-14 |
Family
ID=27506753
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002158241A Abandoned CA2158241A1 (en) | 1994-03-15 | 1995-09-13 | Shoe-wiping mat for rent |
Country Status (4)
| Country | Link |
|---|---|
| US (1) | US5680826A (en) |
| EP (1) | EP0763617B1 (en) |
| JP (1) | JP2667115B2 (en) |
| CA (1) | CA2158241A1 (en) |
Families Citing this family (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP3957383B2 (en) * | 1997-02-14 | 2007-08-15 | 株式会社ダスキン | mat |
| US6332293B1 (en) * | 1997-02-28 | 2001-12-25 | Milliken & Company | Floor mat having antimicrobial characteristics |
| US20020114917A1 (en) * | 1999-06-17 | 2002-08-22 | Seiin Kobayashi | Methods of coloring solution-dyed nylon |
| US6740386B2 (en) * | 2001-05-02 | 2004-05-25 | Burlington Industries, Inc. | Tufted covering for floors and/or walls |
| WO2011095994A1 (en) * | 2010-02-04 | 2011-08-11 | Kannappan Govindaswamy | Method of weaving, processing and finishing a pile fabric |
| TR201517806A2 (en) * | 2015-12-31 | 2016-09-21 | Kipas Mensucat Isletmeleri Anonim Sirketi | OBJECTIVE OF SANDED FABRIC PROPERTIES WITHOUT COTTON YARN TOUCHED FABRIC SANDING PROCESS |
Family Cites Families (15)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3908570A (en) * | 1972-05-26 | 1975-09-30 | Fieldcrest Mills Inc | Patterned tufted fabrics and method of making same |
| JPS531019B2 (en) | 1972-12-12 | 1978-01-13 | ||
| JPS5138598A (en) | 1974-09-30 | 1976-03-31 | Duskin Franchise Co | SEISOYOGANY USENISEIHIN NO SEIZOHO |
| US4010303A (en) * | 1975-04-16 | 1977-03-01 | Akzona Incorporated | Tufted carpet with woven ribbon backing of polyamide and polyester |
| JPS597450B2 (en) | 1980-08-27 | 1984-02-18 | ダスキンフランチヤイズ株式会社 | Matsuto base assembly |
| US4659602A (en) * | 1985-11-12 | 1987-04-21 | Jorgen Birch | Broad spectrum camouflage mat |
| JPS62137029A (en) | 1985-12-09 | 1987-06-19 | 株式会社ダスキン | Production of integrated mat |
| US4808459A (en) * | 1987-09-16 | 1989-02-28 | Collins & Aikman Corporation | Carpet with polyvinylidene chloride latex tuft-lock adhesive coating |
| JPH0266355U (en) * | 1988-11-09 | 1990-05-18 | ||
| JP2662806B2 (en) * | 1988-11-12 | 1997-10-15 | レイテック株式会社 | Tile carpet |
| JPH03294564A (en) * | 1990-04-13 | 1991-12-25 | Oono:Kk | Tufted carpet |
| JPH0418133A (en) * | 1990-05-09 | 1992-01-22 | Toshio Narimi | Fiber yarn for cleaning goods |
| JP2656372B2 (en) * | 1990-07-10 | 1997-09-24 | 株式会社ダスキン | Rental mats that prevent waves |
| JPH04209820A (en) * | 1990-11-30 | 1992-07-31 | Unitika Ltd | Polyster slit yarn |
| US5205233A (en) * | 1992-04-06 | 1993-04-27 | Tapistron International, Inc. | Fabric shift sequencing for pattern producing hollow needle tufting apparatus |
-
1994
- 1994-03-15 JP JP6044444A patent/JP2667115B2/en not_active Expired - Lifetime
-
1995
- 1995-09-12 US US08/527,136 patent/US5680826A/en not_active Expired - Lifetime
- 1995-09-13 EP EP95306397A patent/EP0763617B1/en not_active Expired - Lifetime
- 1995-09-13 CA CA002158241A patent/CA2158241A1/en not_active Abandoned
Also Published As
| Publication number | Publication date |
|---|---|
| US5680826A (en) | 1997-10-28 |
| JP2667115B2 (en) | 1997-10-27 |
| EP0763617A1 (en) | 1997-03-19 |
| EP0763617B1 (en) | 1999-04-14 |
| JPH07250802A (en) | 1995-10-03 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| FZDE | Discontinued |
Effective date: 20050913 |